Summer Term 2001
2001 catalog data: Credit (
Prerequisites: MFGG-370 Engineering Materials
Green sand casting, lost foam casting, permanent mold casting and die casting are discussed. The interrelationships between part design, solidification mode, casting process parameters and the resulting microstructure and properties are examined.
Textbook(s): None
References: Guided lecture notes and supplemental readings from current literature are
provided. Experimental procedures are provided for the laboratory experiences.
Coordinator(s): B. Lee Tuttle, Professor of Manufacturing Engineering
Charles V. White, Professor of Manufacturing Engineering
Course learning
objectives:
A student who successfully completes this course will be able to:
1. Compare the similarities and differences among green sand casting, lost foam casting, permanent mold casting process as the process parameters relate to sound casting production. (Program Outcomes A, C; MFGG PEOs: 1, 2, 3, 7)
2. Discuss the molten metal processing techniques such as fluxing, degassing, filtering inoculation (grain refinement) and modification (modularization) that are performed to control the microstructure in castings. (Program Outcomes: A,C,E; MFGG PEOs: 1, 2, 3, 7)
3. Describe gas porosity and solidification porosity as they occur in castings, and apply the techniques that can be utilized in all casting processes to control these defects. (Program Outcomes: A,C,E,K,O,P ; MFGG PEOs: 1, 2, 3, 6, 7)
4. Analyze a casting to determine the location of casting shrinkage, and then the ability to apply principles of heat transfer to manipulate the location of the shrinkage to the riser. (Program Outcomes: A,C,E,K,O,P; MFGG PEOs: 1, 2, 3, 6, 7)
5.
Use the
6. Determine the size and location of risers to ensure a sound casting with minimal shrinkage porosity. (Program Outcomes: A,C,E,K,O,P; MFGG PEOs: 1, 2, 3, 6, 7)
Prerequisites by
topic:
1. Basic knowledge of metal casting processes
2. Structure, properties and processing of engineering materials
3. Crystal structure
4. Heat treatment of engineering materials
5. Principles of binary phase diagrams
6. Relationship of cooling curve to binary phase diagram
7. Basic mechanical properties of materials and their tests
Topics covered:
1. An overview of metal casting processes and process parameters
2. Review of phase diagrams as related to solidification of castings
3. Thermal analysis of castings
4. Solidification mechanisms in castings
5. Molten metal processing of alloys
6. Control of microstructure during solidification
7. Relationship of casting defects to casting process parameters
8. Differences among green sand casting, lost foam casting, permanent mold casting, and die casting with
respect to casting process parameters
9. Binary and ternary phase diagrams
10. Cooling Curve Analysis
Schedule: Two lecture sessions of 60 minutes per week and two laboratory sessions of 120
minutes
Computer usage: Students will become familiar with the
software.
Laboratory projects: 1. Development of a risering curve for aluminum alloys
2. Application of alternate mold materials to isolate solidification shrinkage in
castings
3. Application of the
solidification shrinkage defects in castings
4. Evaluations of the flow rate, pressure, and lance placement on the degassing
efficiency of an inert gas purging system.
5. Correlation of the solidification rate in castings with Chivorinov's law.
6. Correlation of the effect of mold hardness and mold permeability on the
ability to produce a sound casting.
7. Evaluation of the effect of flow rate, rotor sped, and process time on the rate
of gas removal with a Rotary Impeller Degassing System.
Relationship to
professional component: Three
credits of engineering science and one credit of engineering design.
Prepared by: ___B. Lee Tuttle__________________ Date: __July 1, 2000___